Extendable sleeve for poured concrete deck

ABSTRACT

A tubular passage for poured concrete decks has an intumescent tube held in a two-part, clamshell base. First and second, spaced apart, funnel shaped, diaphragm seals are connected to a first tubular passage or an adjustable length tubular extension. A cap for closing either tube has an inclined outer surface to form a beveled entrance to the passage in the concrete. An aerator box may be connected to the base. Hinged ends on the base allow the shape and length of support to be altered.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation in part of application Ser. No.14/072,650, titled Extendable Sleeve for Poured Concrete Deck, filedNov. 5, 2013, the complete contents of which are hereby incorporated byreference.

STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT

Not Applicable

BACKGROUND

Concrete floors in multistory buildings are poured onto flat plywooddecks that are later removed, or poured onto corrugated sheet metalsupports that are left in place. In both cases passages through theconcrete decks are needed for various plumbing pipes, electricalconduits, ventilation tubes, etc. In the event of fire or flooding,these passages through the concrete must be sealed in order to preventpassage of air, smoke, fire or water. Current fire and smoke seals usean intumescent material that involves taking flat strips of intumescentmaterial and fastening it around a cylindrical container ofpredetermined diameter using adhesives or other mechanical fasteners.The intumescent material often includes a graphite or fibrous materialthat can be messy and hazardous to handle and ingest, and oftencarcinogenic. Fastening the flat strips to the passage tubes is laborintensive, prone to errors and may raise health concerns. Because theintumescent material has a limited expansion, and because manyapplications require effective internal smoke and water sealing, thecontainers are generally made to order for specific pipe sizes. Further,because of the variable thickness of concrete slabs specified by buildercontractors, manufacturers are forced to either custom build thecontainer hardware or to supply containers in large increments thatforce customers to buy extra kits or cut the container on-site. In anyevent, current options do not allow economically effectivemanufacturing-to-specification solutions. Upon installation, the pipesactually used may differ from those initially planned or may be offsetfrom the center more than the expansion of the intumescent material canaccommodate, so the prefabricated, size specific fire seals may not fit,or fit as well as intended or needed, or may not work as well asdesigned during actual use. There is thus a need for an improved fireseal and container for intumescent material that will accommodate awider variety of pipe diameters within a single device be more easilyassembled and installed, and better suit variations in pipe location andslab thickness than devices currently used.

The passages through the concrete are formed by fastening a passagetube, typically plastic or metal to the support before the concrete ispoured. The concrete decks vary greatly in thickness from four to eightinches, but may be as thin as two inches and as thick as 18 inches ormore. Current passage tubes are premade to specific diameters andlengths, making it difficult to stock a sufficient supply for use and toaccommodate variations in the passage tubes at the job site. There isthus a need for a more flexible length passage tube able to accommodatepipes of varying diameters.

The tubes must be fastened to the plywood support, or have a larger baseto span enough corrugations to provide a stable tube support, especiallyfor smaller diameter, longer passage tubes. Providing a large basesuitable for corrugated supports is expensive and unnecessary forplywood supports. Moreover, several pipes may sometimes be clusteredtogether when passing through the floor and in such cases the individualpassage tubes need to be placed close together at distances driven byCISPI standards. If the passage tube has a large base for use on acorrugated support, it becomes difficult to achieve the desired spacingwhen the large support is used on either plywood or corrugated supports.There is thus a need for an improved tube support more suitable for thedifferent support applications.

The passage tubes are provided in different lengths to accommodate thevariable thickness of the concrete decks. Long passage tubes aresometimes cut shorter, wasting material and often resulting ininaccurate cuts as the worker may measure wrong. Sometimes an extensioncan be added to a shorter passage tube to increase the overall length,but again workers can measure wrong, resulting in non-compliant passagesthrough the concrete. Also, the extended tubes may be hit, kicked orstood on and in such cases extension tubes may break. There is thus aneed for an improved passage tube with a sturdier, easily adjustedlength.

In addition to a smoke and fire seal the passages through the concretemust provide a water seal around the pipes or conduits passing throughthe passage tube. Flat, plastic or rubber sheets are used with holes cutout for the pipe to pass through and these are also installed in thepassage tube at the time the passage tubes are made. If the pipes aretoo large for the holes the sheets tear, if the pipes are too small theseal is poor and if the pipes are offset from the holes in the sheetsthen inadequate seals may formed. There is thus a need for an improvedwater seal in passage tubes.

When the concrete deck is poured around the passage tubes the upper endof the tubes are blocked to prevent concrete from filling the passagetube. Mechanical trowels and riding trowels are used to finish theconcrete surfaces of the poured decks and the closed ends of the tubesare often covered with a thin layer of concrete in doing so. Theconcrete covering makes it difficult to locate the passage tubes.Workers sometimes tape nylon strands to items over which concrete ispoured so the strands extend out of the concrete surface after finishingand bend for the troweling machines. But taping strands to things istime consuming, may be unintentionally omitted or not planned at all,and the tape may tear lose or otherwise fail to restrain the strandsduring pouring of the concrete or troweling. There is thus a need for animproved way to locate passage tubes in freshly poured concrete floors.

The passage tubes may need to be configured differently depending onwhether they are to contain metal or cast iron pipes or plastic pipes,in part because the water seal with the outside of a cast iron pipe hasdifferent requirements than for plastic or copper pipes. For example,exterior pipe diameters differ significantly between pipe types of eventhe same nominal internal size. Workers can sometimes look inside thepassage tube to see the opening size in the water seal but that is timeconsuming, and invites error from judging opening diameters by visuallylooking down a dark tube of varying length. There is thus a need for animproved way to allow workers to identify the types of pipes a passagetube is designed to accommodate.

After concrete floors are poured to entrain passage tubes there may bespills of large volumes of water. It is desirable to prevent such waterspills from entering the passages and passing through the passages.There is thus a need for an improved passage tube for entrainment inconcrete floors.

BRIEF SUMMARY

An assembly is provided to form an adjustable length, tubular passage inpoured concrete decks. The assembly has a tubular cylinder ofintumescent material held in a two-part base by a clip supporting thebottom of the tubular cylinder of intumescent material and fastened tothe base. A first, cylindrical tube engages the base's top to clamp adiaphragm seal against the base. The seal has a pipe opening and afunnel shape to accommodate pipe offsets and to better seal against thepipe. The first tube has spaced, radially extending, parallel ridges atpredetermined distances from the base. Cutting between the ridgesadjusts the length of the tubular passage to known lengths. Longitudinalchannels separate the ridges into first and second sets of ridges.Printed indicia in the channels or in the grooves between adjacentridges can state the lengths. The two sets of ridges can be at differentdistances from the base for greater variability of length adjustment. Acylindrical extension tube fits over the first tube and has inwardlyextending lugs on opposing sides of a first end of the extension tube.The lugs pass along the longitudinal channels with the extension tubebeing rotated to engage the lugs with various ridges to adjustably fixthe passage length to the end of the extension tube. A second end of theextension tube optionally engages the base bottom for use withcorrugated supports. A cap with repositionable locating filamentsoptionally closes the either the first extension tube or the first tube,depending on need. The locating filaments are attached to the undersideof the cap and extend inside nested first tube and extension tube forshipment, with the filaments being repositioned to connect to theoutside of the cap and extend along the longitudinal axis during use.The locating filaments connect to the cap below the outer surface so thefilaments bend during troweling of the concrete and extend above thefinished concrete surface to allow users to locate the tubular passageafter concrete finishing.

In more detail, there is advantageously provided a tubular passageassembly for poured concrete decks formed on a support surface. Theassembly includes a base having a cylindrical sidewall with an upper endand an opposing bottom end and extending along a longitudinal axis. Theupper end of the sidewall has an inward extending upper flange defininga circular opening encircling the longitudinal axis. The lower end ofthe base has an outward extending base flange to support the base on thesupport surface during use. A cylindrical tube of intumescent materialencircles the longitudinal axis and fits inside and adjacent to thesidewall and is restrained from movement in a first direction along thelongitudinal axis by the upper flange. A retaining clip has an annularportion abutting the bottom of the tubular cylinder of intumescentmaterial to restrain the tubular cylinder of intumescent material frommovement in a second direction along the longitudinal axis. Theretaining clip has a plurality of tabs extending through the basesidewall to restrain movement of the retaining clip along thelongitudinal axis during use.

In addition to the base assembly, the tubular passage assembly mayinclude a flexible diaphragm seal having an outer periphery engaging anupper end of the base and having an inner periphery defining an openingencircling the longitudinal axis during use. A portion of the diaphragmadjacent the inner periphery has a funnel shape extending out of a planeorthogonal to the longitudinal axis through the outer periphery.

In further variations, the first tube has opposing upper and lower endswith the lower end configured to engage the base. The first tube alsomay have an inward extending flange adjacent the lower end configured toengage the periphery of the diaphragm and press it against the base toform a fluid tight seal when the first tube is engaged with the base.The first tube may further includes a first set of parallel ridgesextending outward from the first tube with each of the first ridges in aplane orthogonal to the longitudinal axis and the first set of ridgeseach extending less than half way around the first tube. The first tubemay also include a second set of parallel ridges extending outward fromthe first tube with each of the ridges in a plane orthogonal to thelongitudinal axis. The second set of ridges each extends less than halfway around the first tube and located on an opposing side of the firsttube than the first set of ridges. The first and second ridges each haveends spaced apart to define first and second longitudinal channels onopposing sides of the first tube. The first tube may further include afirst set of visible indicia adjacent a plurality of the first set ofridges where the indicia defines a distance from the bottom of the baseto the visible indicia associated with each of the plurality of thefirst set of ridges. The first tube may also have a second set ofvisible indicial adjacent a plurality of the second set of ridgesdefining a distance from the bottom of the base to the visible indiciaassociated with each of the plurality of the second set of ridges, withat least one of the first and second set of indicia indicating adistance specified in metric or English distance units.

In further variations, a plurality of the ends of two adjacent ridges inthe first set of ridges are joined by first axially extending endsegments with the first axially extending end segments joining only twoadjacent ridges. A plurality of second axially extending end segmentsmay join adjacent ridges which ridges are each joined to a different oneof the first axially extending end segments. The first axially extendingend segments are located a first circumferential distance from a centerof the first channel and the second axially extending end segmentslocated a second circumferential distance from the center of the firstchannel with the second circumferential distance being greater than thefirst circumferential distance to form a first circumferential recess ateach second axially extending end segment. Further, a plurality of theends of two adjacent ridges in the second set of ridges may be joined bythird axially extending end segments with the third axially extendingend segments joining only two adjacent ridges. A plurality of fourthaxially extending end segments may join adjacent ridges which are eachjoined to a different one of the third axially extending end segments.The third axially extending end segments are located a thirdcircumferential distance from the center of the first channel and thefourth axially extending end segments located a fourth circumferentialdistance from the center of the first channel, with the fourthcircumferential distance being greater than the third circumferentialdistance to form a second circumferential recess at each fourth axiallyextending end segment.

In still further variations, the base may have an outwardly extendinglimit stop and the first tube has a tab located to hit the limit stop asthe first tube engages the base so as to position the first tube a knowndistance from a bottom of the base and ensure proper compression of thediaphragm seal. Further, the base may have external screw threadsthreadingly engaging internal screw threads on the lower end of thefirst tube to engage the first tube to the base, with the base and firsttube each having a motion limit stop located to engage when the firsttube is at a predetermined distance from the bottom of the base.Further, the base may be formed of two segments separated along a planethrough the longitudinal axis but fastened together to form the baseafter the tubular cylinder of intumescent material is inserted into atleast one segment of the base.

In still further variations, the tubular passage assembly may include afirst extension tube having opposing top and bottom ends with the topend threaded internally and the bottom end threaded externally with thesame threads as the top end. The bottom end of the first extension tubehas first and second locking lugs each extending inward from a differentopposing side of the first extension tube with the first and secondlocking lugs being sized and located to slide along the first and secondchannels, respectively. Rotation of the first extension tube places eachlocking lug between two adjacent ridges of one of the first or secondsets of ridges. Further, the upper end of the first extension tube mayhave internal threads sized to threadingly engage external threads onthe cap with the first extension tube being large enough to fit over thefirst tube. This first extension tube may also act as a lower extensionin cooperation with threads formed in the base located to threadinglyengage threads on one end of the extension tube. Still further,additional extension tubes may be threaded into the first extension tubeif needed, to further lengthen the tube.

In further variations, the flexible diaphragm is made of silicone or TPR(thermo plastic rubber) and has sidewalls curving upward away from thebase and toward the longitudinal axis, with the curved sidewalls locatedintermediate the inner and outer periphery. The base flange may extendalong at least two opposing sides of the base and may further include afirst stabilizing plate configured to releasably fasten to one of the atleast two opposing sides of the base flange and restrain rotation of theupper end of the base toward the juncture of the base flange with thestabilizing plate. A second stabilizing plate may be provided on anopposite side of the base flange. Further, the stabilizing plate(s) maybe joined to the flange by a living hinge and screwed or nailed to theconcrete forms for stabilizing purposes, or rotated along the livinghinge toward the flexible diaphragm and latched there to keep the plateout of the way if not being used to stabilize the base.

An improved cap is also provided for use with the tubular passageassembly. The cap has a circular top having an upper and lower side withan annular skirt depending therefrom. First and second latches eachextend inward from an opposing side of the skirt. The latches areconfigured to releasably engage one of the ridges on the outside of thefirst tube in order to fasten the cap to the first tube. Also, the capmay have external threads for attaching to the first extension tube.Between the threads and the top of the cap, the cap may have an inwardlytapered peripheral edge that forms a short, conical or beveled edge inthe concrete when the cap is removed. The cap has a connector on atleast the upper side of the top with the connector located in a recess.A filament base has at least one filament extending therefrom and isconfigured to releasably engage the connector to hold the at least onefilament generally parallel to the longitudinal axis. The juncture ofthe filament to the filament base being located below the upper side ofthe top and sufficiently far from the recess edge so that the at leastone filament can be troweled against the upper side of the top and notbreak, the filament having a length sufficient to be visible after thecap is covered with a thin layer of troweled concrete during use.

There is also provided a kit for forming a tubular passage along alongitudinal axis for passage of a pipe through a poured concrete deck.The kit includes a base assembly having a base formed of two opposinghousing portions fastened together to form a cylindrical sidewallportion containing a tubular cylinder of intumescent material adjacentthe cylindrical sidewall portion. The tubular cylinder of intumescentmaterial encircles the longitudinal axis and has its motion limited in afirst direction along the axis by the housing and has movement in theopposing direction along the axis limited by a clip engaging thehousing. The kit may include a first flexible diaphragm seal having acentral opening selected to seal against a range of pipe diametersduring use. The seal has a funnel portion between an outer periphery andthe central opening. The kit may also include a first cylindrical tubeconfigured to fasten to a top of the base assembly during use andencircle the longitudinal axis during use. The first tube and base areconfigured to clamp a periphery of the flexible diaphragm between themsufficiently to form a fluid tight seal.

In further variations, the first tube of the kit has a plurality ofoutwardly extending, equally spaced ridges on an exterior surfacethereof and extending along a majority of a length of the first tube.The kit also may include a first cylindrical extension tube having afirst end configured to fit over the first tube and having at least onelug configured to engage a selected one of the plurality of outwardlyextending ridges to releasably fasten the first extension tube to thefirst tube. The kit may further include a first tube that fastens to thetop of the base by a double lead threaded connection. The base may haveinternal, double lead threads on a bottom thereof which threads encirclea lower portion of the tubular cylinder of intumescent material and areconfigured to threadingly engage mating threads on the first cylindricalextension tube. The kit may also include a second flexible diaphragmseal clamped between two opposing rings may also be provided, with atleast one of the rings having threads or snap locks configured toconnect to the housing or to the first tube.

The first tube may also form a separate improvement. The first tube mayform a tubular passage along a longitudinal axis for passage of a pipethrough a poured concrete deck. The first tube may include a tubularcylinder having an opposing upper and lower ends extending along thelongitudinal axis during use. The cylinder has a first diameter along amajority of its length with a larger diameter lower end and internalthreads around the inside of the larger diameter lower end. The cylindermay have a first plurality of parallel ridges extending radially outwardalong a majority of a length of the cylinder and a second plurality ofparallel ridges extending radially outward along a majority of a lengthof the cylinder and axially offset from the first set of ridges. Thefirst and second sets of ridges are preferably separated by first andsecond channels extending parallel to the longitudinal axis. In furthervariations, a plurality of the ridges in the first set has distal endsjoined by vertical segments at the distal ends of said plurality ofridges.

In the above tubular passages and kits, for use on corrugated supports,a hole is cut through the corrugation and the base positioned over thehole. An extension tube the same as the first extension tube is passedupward through the hole in the corrugation and fastened to the bottom ofthe base. The extension tube may have one or more pilot holes extendinginward from an outer surface of the extension tube, with the pilot holespreferably being blind holes but located so the hole is aligned betweenadjacent ridges on the first tube so that a self-threading fastener(also optionally provided with the kit) may pass through the blind holeand between adjacent ridges to fasten the extension tube to the firsttube.

Preferably the base has mating screw threads encircling the tubularcylinder of intumescent material and thus outward of that cylinder andaccessible from the lower side of the base. To enable the screw threadsto extend into the base and encircle the tubular cylinder of intumescentmaterial the retaining clip is offset so that the tabs bend upward toform an offset accommodating the bottom screw threads with the tabs thenextending outward through openings in the cylindrical sidewalls of thebase that encircle the tubular cylinder of intumescent material. Asneeded, a removable adhesive cover or cap is placed over the bottom ofthe base to keep debris from entering the base during shipment, duringinstallation, during pouring of the concrete and during application offire retardant spray. The removable adhesive cover or cap may be removedand placed on the open end of an extension tube that is screwed into thebottom of the base if desired.

The base flanges may have two removable tabs formed in the base. One tabmay indicate metal and the other plastic. If the shaped diaphragm andbase assembly are selected for use with metal pipes passingtherethrough, then the plastic tab is removed so that a user can seefrom looking at the tab on the base that the passage tube is intendedfor use with metal pipes. If the shaped diaphragm is selected forplastic pipes then the metal tab is removed so that a user can see fromlooking at the tab on the base that the passage tube is intended for usewith plastic pipes. The indicia indicating metal or plastic pipe ispreferably visible from at least the upper side and preferably visiblefrom both the upper and lower sides of the base. Alternatively, theindicia may consist of color-coded inserts installed in openings in thebase flange.

There is also advantageously provided a kit for an assembly forming atubular passage for poured concrete decks formed on a support surface.The kit and assembly include a base having a cylindrical sidewall withan upper end and an opposing bottom end and extending along alongitudinal axis. The upper end of the sidewall have an inwardextending upper flange defining a circular opening while the lower endof the base has an outward extending base flange to support the base onthe support surface during use. A tubular cylinder of intumescentmaterial is provided and fits inside and adjacent to the sidewall whereit encircles the longitudinal axis and is retained in position along thelongitudinal axis during use. Various retaining mechanisms for theintumescent material can be used as described herein, and as known tothose skilled in the art. The kit and assembly also include a firstflexible diaphragm seal having an outer periphery engaging an upper endof the base and having an inner periphery defining an opening encirclingthe longitudinal axis during use. A portion of the diaphragm adjacentthe inner periphery has a funnel shape extending out of a planeorthogonal to the longitudinal axis through the outer periphery. The kitand assembly may also include a first tube having opposing upper andlower ends with the lower end configured to engage the base. The firsttube may have an inward extending flange adjacent the lower endconfigured to engage the periphery of the diaphragm and press it againstthe base to form a fluid tight seal when the first tube is engaged withthe base. The first tube further includes a first set of parallel ridgesextending outward from the first tube with each of the ridges in a planeorthogonal to the longitudinal axis and spaced apart a first distance.The kit and assembly also include a first extension tube having asidewall with opposing top and bottom ends. The bottom end of the firstextension tube has first and second locking lugs each extending inwardfrom a different opposing side of the first extension tube. The firstand second locking lugs may be sized and located to slide along thefirst and second channels, respectively, with rotation of the firstextension tube placing each locking lug between two adjacent ridges ofthe first set of ridges when the first extension tube is centered on thelongitudinal axis and overlaps a portion of the first tube. The kit andassembly also may include a pilot hole extending partially through thesidewall from an exterior side of the first extension tube. The pilothole is located on the extension tube relative to one of the first andsecond locking lugs so that the pilot hole is located in a radial planepassing between two adjacent first ridges.

In further variations, a self-tapping threaded fastener extends throughthe pilot hole and wall of the extension tube and into the first tubebetween two adjacent first ridges to connect the first extension tube tothe first tube. There may be two pilot holes on opposing sides of thefirst extension tube and the kit and assembly may further include twothreaded fasteners. Each fastener may extend through a different one ofthe pilot holes and wall of the extension tube and into the first tubebetween two adjacent first ridges to connect the first extension tube tothe first tube. The first set of ridges preferably extends less thanhalf way around the first tube and the first tube may include a secondset of parallel ridges as described herein.

The kit and assembly may also include a second flexible diaphragm sealhaving a circular periphery located between a connecting ring and aclamping ring and held therebetween. The second diaphragm seal has aninner periphery defining an opening encircling the longitudinal axisduring use with a portion of the diaphragm adjacent the inner peripheryhaving a funnel shape extending out of a plane orthogonal to thelongitudinal axis through the outer periphery and extending in the sameaxial direction as the funnel shape of the first diaphragm during use.The connecting ring is configured to engage the upper end of the firsttube, preferably by threads or a snap-lock connection. An O-ring sealmay be located between an outward facing surface of the connecting ringand an inner surface of the first tube, with the O-ring seal locatedbetween the first and second diaphragm seals during use.

The kit and assembly may include a circular top having opposing upperand lower surfaces with a depending skirt and an inclined sidewalllocated between the depending skirt and the top surface of the cap. Theinclined sidewall has a larger diameter adjacent the top surface of thecap and a smaller diameter adjacent the skirt. The inclined sidewall hasa diameter larger than an outer diameter of the top end of the firstextension tube so as to extend outward of the first extension tube andform a beveled surface in concrete entraining the cap and firstextension tube during use when the cap is fastened to the firstextension tube. The inclined sidewall has a diameter larger than anouter diameter of the top end of the first tube so as to extend outwardof the first tube and form a beveled surface in concrete entraining thecap and first tube during use when the cap is fastened to the first tubeduring use. The cap may have the other features described herein.

The assembly or kit may also include an aerator box. The aerator box mayhave two parallel side walls joined at opposing ends to a different oneof two opposing end walls to encircle the longitudinal axis and form thesides of an enclosure. The side walls and end walls are connected to atop having a cylindrical flange configured to connect to the bottom ofthe base. The parallel side walls are spaced apart the same distance astwo opposing sides of the base flange. The two opposing end walls arespaced apart a larger distance but less than twice the distance betweenthe parallel side walls. At least some of the end walls and side wallshave a lower end with an outwardly extending flange suitable forfastening the aerator box to a concrete pouring form.

The kit and assembly may also include a variation of the base whereinthe base flange has two opposing and parallel sides and two opposingends. Each of the opposing ends has a hinge extending across the endorthogonal to the sides and forming a distal end portion that may rotateabout the hinge toward the sidewall of the base. The hinge may be aliving hinge formed in a base flange made of a polymer. The hingeddistal end of the base flange, the aerator box, the cap with theinclined peripheral edge, and the second module may each comprise aseparate improvement.

The kit and assembly may also include an elongated support plate havingan opening encircling the longitudinal axis and allowing access to thebottom of the base opposite the cylindrical sidewall of the base. Thesupport plate has a length sufficient to extend beyond the ends of twoopposing ends of the base flange. The support plate may have a generallyrectangular and planar shape with a plurality of fingers extending froman upper surface of the plate. The fingers may be configured to piercethe base flange and connect the support plate to the base flange. Aplurality of the fingers may also be configured and located to extendthrough a plurality of slots extending through the base flange toconnect the support plate to the base flange.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features and advantages of the invention will becomemore apparent in light of the following discussion and drawings, inwhich like numbers refer to like parts throughout, and in which:

FIG. 1 is an exploded perspective view of an extendable sleeve forforming a tubular passage in a poured concrete floor;

FIG. 2 is a top perspective view of a base of FIG. 1;

FIG. 3 is a bottom perspective view of the base of FIG. 2;

FIG. 4 is a top perspective view of an assembly including a base and afirst tube of the extendable sleeve of FIG. 1;

FIG. 5 is a top perspective view of the assembly of FIG. 4 furtherincluding a first extension tube;

FIG. 6 is a sectional view of the assembly of FIG. 5, taken along 6-6 ofFIG. 5;

FIG. 7 is a partial perspective view of a portion of FIG. 6 showing thejuncture of the first tube and the extension tube;

FIG. 8 is a partial perspective view of a portion of FIG. 5 showing thejuncture of the first tube and extension tube;

FIG. 9 is a top perspective view of the extendable sleeve of FIG. 1 witha second extension tube thereon;

FIG. 10 is a top perspective view of the extendable sleeve of FIG. 1;

FIG. 11 is a bottom perspective view of the base and first tube and capof FIG. 1;

FIG. 12 is a section view of the extendable tube of FIG. 6 with a capand locating filaments thereon in a position for shipping;

FIG. 13 is a top perspective view of a cap of FIG. 1;

FIG. 14 is a bottom perspective view of the cap of FIG. 11, withlocating filaments in a shipping position;

FIG. 15 is a top exploded perspective view of a base, first tube and capof FIG. 1 with the first tube cut to a very short length;

FIG. 16 is a bottom, exploded, perspective sectional view of the baseand cap of FIG. 15;

FIG. 17 is a top, exploded perspective view of a the extendable sleeveof FIG. 1 with a bottom extension tube;

FIG. 18 is a perspective view of the juncture of a corrugated formstabilizing plate with the base of FIG. 17;

FIG. 19 is a bottom perspective view of the assembly of FIG. 17;

FIG. 20 is a bottom perspective view of the assembly of FIG. 17 but withthe bottom cover removed;

FIG. 21 is a bottom, perspective section view of the diaphragm seal ofFIG. 1;

FIG. 22 is a section view of the extendable sleeve of FIG. 17 on acorrugated support;

FIG. 23 is a sectional view taken along 23-23 of FIG. 24 a;

FIG. 24 a is a top view of two halves of the base housing, each of adifferent base, joined together;

FIG. 24 b is a side view of the joined half-housings of FIG. 24 a;

FIG. 25 a is a perspective view of a tubular cylinder of intumescentmaterial;

FIG. 25 b is a perspective view of a tubular cylinder of intumescentmaterial with interior ribs or crennelations encircling a pipe;

FIG. 26 a is a perspective, sectional view taken along section 26 a-26 aof the base of FIG. 26 b;

FIG. 26 b is a perspective view of a further embodiment of the base ofFIG. 1;

FIG. 27 is an exploded perspective view of a water seal for use with thepassage tube assembly 10 of FIG. 1;

FIG. 28 is a perspective view of the water seal of FIG. 27 in anassembled configuration;

FIG. 29 is a top view of the water seal of FIG. 28;

FIG. 30 is a sectional view taken along 30-30 of FIG. 29;

FIG. 31 is a perspective view of a water dam for use with the passagetube assembly 10 of FIG. 1;

FIG. 32 is an exploded view of the water dam of FIG. 31;

FIG. 33 is a cross-sectional view of the water dam of FIGS. 31 and 32;

FIG. 34 is an exploded perspective view of an aerator for use with thepassage tube assembly 10 of FIG. 1;

FIG. 35 a is a side view of the assembled aerator and passage tube ofFIG. 34;

FIG. 35 b is a front view of the assembled aerator and passage tube ofFIG. 35 a; and

FIG. 35 c is a sectional view taken along 36 c-36 c of FIG. 35 b;

FIG. 36 is a perspective view of a further embodiment of a base flange;

FIG. 37 a is a perspective view of a further embodiment of the cap ofFIGS. 13-15;

FIG. 37 b is a side view of the cap of FIG. 37 a;

FIG. 37 c is a side view of the cap of FIG. 37 a with the inclinedsurface more radially outward;

FIG. 38 a is a perspective view of a base of FIG. 1 with modifiedsupporting plates;

FIG. 38 b is a top view of the base of FIGS. 38 a and 38 c;

FIG. 38 c is a side view of the base of FIG. 38 a;

FIG. 38 d is a bottom view of the base of FIGS. 38 a and 38 c;

FIG. 39 is a perspective view of a passage tube assembly with threadedfasteners extending into ports to lock parts together.

FIG. 40 is a perspective view of the assembled aerator and passage tubehaving ring stiffeners on an outer extension tube; and

FIG. 41 is a side view of an extension tube having longitudinalstiffeners.

DETAILED DESCRIPTION

Referring to FIGS. 1-20 a passage tube assembly is provided having abase 12 formed of a housing 14 having two-parts 14 a and 14 b whichclamp radially about a longitudinal axis 16 of the passage tube assembly10 and base 12, with fasteners 18 a clamping mating bosses 18 b, 18 c onopposing housing parts together in order to secure the housing parts 14a, 14 b together. The base preferably has a flange 17 extending outwardfrom the lower end of the base 12. As used herein, the relative termsinner and outer, inward and outward, are with respect to longitudinalaxis 16. The relative terms above and below, upper or lower, upwards anddownwards are also relative to the position along longitudinal axis 16with respect to flange 17 on base 12 in the orientation of FIGS. 1 and4-6, so that housing 14 and passage tube assembly are above base flange17.

Referring especially to FIGS. 1-3 and 6, the housing parts 14 a, 14 beach have a curved sidewall extending along the longitudinal axis 16 andan inwardly extending lip 20 on an upper end to restrain upward axialmovement of an tubular cylinder 22 of intumescent material placed insidethe housing 14. The housing parts 14 a, 14 b may each have a lower lip(not shown) at a lower end to restrain downward axial movement of thetubular cylinder 22 of intumescent material, in which case the tubularcylinder 22 of intumescent material is placed in one part of the base 12or housing parts 14 a, 14 b before the two parts are joined and fastenedtogether to form the base 12. But using two, (one upper and one lowerlip) may complicate molding so preferably only one lip is used, upperlip 20, with the tubular cylinder 22 of intumescent material held at thebottom of the base 12 by a retaining clip 24 having tabs 26 that passthrough mating openings 28 in each of the two-part housing 14 as the twoparts of the housing are assembled.

The retaining clip 24 has an annular bottom portion 30 to hold thebottom of the tubular cylinder 22 of intumescent material, with theannular bottom portion being offset axially from four extending tabs 26for reasons discussed later. After assembly, the tabs 26 extend from theinside to the outside of housing 14 and the tabs are then bent to lockthe retaining clip 24 in place so the tubular cylinder 22 of intumescentmaterial is constrained on three sides by the annular bottom portion 30of the clip 24 and the base's sidewall 19 and upper lip 20, so thatthermal expansion of the tubular cylinder 22 of intumescent material isdirected generally inward toward longitudinal axis 16.

The two parts of housing 14 a, 14 b are fastened together by snapslocks, threaded fasteners, other mechanical locks, or adhesives, withscrews 18 being illustrated in the Figures. The lower end of the base 12has flange 17 extending outward from the base's sidewall 19 with holes32 in the flange to allow the flange to be nailed, screwed or otherwisefastened to a support 33. That provides an easily molded housing 14 thatmay be quickly assembled to form base 12, with retaining clip 24 holdingthe tubular cylinder 22 of intumescent material in place within the base12.

The tubular cylinder 22 of intumescent material may be a continuousannular ring or a split ring with two adjacent ends separated by a slot.However, the cylinder 22 may also be formed by methods obtained fromprior art, including rolled shapes of intumescent materials. The tubularcylinder 22 of intumescent material is preferably preformed for easy ofassembly. The tubular cylinder 22 of intumescent material may be formedin a corrugated shape to expand faster and to expand to a greaterdistance than previously achieved.

Referring to FIGS. 1-3 and 11-12, the upper end of the base 12 may haveexternal threads 34 so that a lower end of a first sleeve or tube 36,preferably a graduated tube 36, can threadingly engage the base 12 viamating internal threads 35 (FIG. 12) on the inner surface of the firsttube 36 adjacent the lower end of the first tube 36. By graduated, it ismeant the outer surface of the tube 36 has physically protruding lengthindicators, described later. Advantageously, the cylindrical wallforming first tube 36 is generally concentric with the lip 20 on thebase 12, requiring a lateral, outward offset, stepped or enlargedportion 37 so that the bottom end of first tube is larger in diameterthan the remaining upper portion of tube 36, with the internal threads35 formed on that enlarged stepped portion.

The threads 34 are preferably double lead threads, with one lead on eachhalf 14 a, 14 b of the housing. Thus, the mating threads 35 on firsttube 36 are also preferably double lead threads. A rotation stop 38 a onsidewall 19, just below the threads 34 abuts a mating stop 38 b on thebottom end of first tube 36 in order to limit the engagement of matingthreads on the base 12 and first tube 36 and also accurately positionsthe first tube 36 relative to the base 12 and particularly positions thetube 36 relative to base flange 17.

As best seen in FIGS. 1, 6, 12, 16 and 21, the first tube 36 clamps anouter periphery of a shaped seal diaphragm 40 against the cylindricalwall forming base 12, preferably against the inwardly extending upperlip 20 of the base 12. The first tube 36 may have an inwardly extendingflange 39 (FIG. 12, 16) located concentric with the location of upperlip 20 or another portion of base 12 to squeeze and seal against theseal 40. The inward flange 39 is preferably at the juncture of theenlarged or stepped portion 37 with the remainder of the first sleeve ortube 60 so as to provide a larger radially extending surface to abut theperiphery of diaphragm seal 40. The depending skirt 45 of the diaphragmseal 40 is advantageously located between an inner surface of thestepped portion 37 and an outer surface of the base 12 adjacent lip 20.Thus, the lip or skirt 45 on the diaphragm seal 40 resists radiallyinward motion when it is clamped between the base 12 and the first tube36. That provides a strong, fluid seal for the outer periphery ofdiaphragm seal 40 with the mating base 12 and first tube 36. Theperiphery seal is believed capable of meeting and preferably exceedingregulatory fluid retention requirements.

The diaphragm 40 has a central opening 42 that is preferably surroundedby an inclined or curved, funnel shaped wall 44 that encircles anddefines opening 42. As used herein, the term “funnel shaped” includeswalls that are straight and inclined (e.g., like a cone) and alsoincludes curved walls. The funnel shaped wall 44 in turn preferablyjoins a generally planar annular portion 43 having a depending skirt 45at an outer periphery thereof. The opposing surfaces of the base 12 andthe first tube 36 advantageously, but optionally have sealing surfaces,such as opposing tongue-and-groove configurations, in order to furtherensure the parts sealingly engage opposing surfaces of the diaphragmseal 40. The opposing surfaces of the base 12 and first tube 36 clampthe outer periphery of the diaphragm seal 40 adjacent the dependingflange 45 and in the flat annular portion 43 near the juncture with theflange 45.

In use, a pipe extends along longitudinal axis 20 and through theopening 42 which seals against the outer surface of the pipe. Theopening 42 is selected to be sufficiently smaller in diameter than theouter diameter of the pipe that a fluid tight seal is establishedmeeting and preferably exceeding regulatory requirements. The pipebasically stretches the elastic opening 42 and funnel shaped portion 44to form a friction seal with the pipe. Further, the base 12 and pipe arefit relative to each other so the pipe passes through the diaphragm seal40 in the axial direction along which the funnel shaped portion 44 isdirected, the upward direction. That allows fluid collected between theinside of the first tube 36 and the outside of the pipe to press thefunnel shaped portion 44 against the pipe further increasing the sealingforce. As desired, the funnel shaped portion 44 may have concentricridges encircling the opening 42 in order to increase the grip betweenthe funnel shaped portion 44 and the pipe during use, and to furtherincrease the water seal between the parts.

The funnel shape wall 44 also allows lateral movement of the opening 42in order to accommodate pipe locations that are offset from the desiredcenter position along axis 16. The curved, funnel walls 44 also allowmore flexibility in the opening 42 before tearing and may lie againstthe pipe to provide a better seal. An elastomeric or rubber diaphragm 40is believed suitable, preferably silicon or neoprene or Thermo PlasticRubber (TPR). The seal 40 is preferably made of a thin, flexiblematerial. As used herein for the seal 40, thin means a thickness betweenopposing surfaces that is less than about 10% the diameter of the sealat the outer periphery and preferably less than 5% of the diameter ofthe seal at the outer periphery. The opening 42 is smaller than thediameter D of the smallest pipe that is intended to be passed throughthe tubular passage assembly 10 and seal 40 so the pipe stretches theopening 42 and creates a frictional grip to help form a water seal. Pipediameters D from 0.5 inches to 4 inches are common, with largerdiameters D up to 8 inches being less common.

Referring to FIGS. 1 and 4-12, the first tube 36 has a first and secondset of outwardly extending ridges 46, 48, respectively formingintervening slots between the respective ridges of each set. The firstridges 46 and intervening first slots each extend about half way arounda first side or first partial circumference of the first tube 36. Thesecond set of ridges 48 and second slots between those second ridgesextend about half way around the opposing, second side or second partialcircumference of the first tube 36. The ridges 46, 48 on the first andsecond sides of the first tube 16 are equally spaced apart about thedistance of a saw blade used by construction workers. The first set ofridges are offset from the second set of ridges, with the first set ofridges being spaced in fractions of an inch and the second set of ridgesbeing spaced metrically, preferably in millimeters. Visible indicia 50(FIGS. 1 & 7) on the first tube 36 discloses a distance from the bottomof the base to each slot, or to the bottom of each ridge (46, 48)forming the slot, so that a worker can cut the first tube 36 to desired,known length by cutting at a slot, with the saw blade guided by theopposing ridges 46 or 48 on each side of the slot. The ridges may beviewed as graduations on the outside of the first tube 36, which is whythe first tube 36 may also be referred to as a graduated tube.Regardless of terminology, the graduated ridges 46, 48 and printedindicia 50 identify a plurality of graduated distances from the bottomof the flange 17 of base 12.

The first and second sets of ridges 46, 48 and their intervening slotsare in radially aligned planes extending orthogonal to axis 16. Thesesets of ridges 46, 48 are separated by first and second longitudinalchannels 52 a, 52 b located on opposing sides of the first tube 36. Asdesired, the printed indicia 50 may be located in one or bothlongitudinal channels 52 a, 52 b, or on the outer sides of cylinder 36in the spaces between adjacent ridges 46 or 48. The ends of two adjacentridges 46 or two adjacent ridges 48 within each set of ridges may bejoined by axially extending end segments 54 (FIG. 7), with alternatingpairs of ridges joined by offset end segments 56 (FIG. 7) that areoffset circumferentially a short distance from end segments 54 eachother to form staggered axial end connections. A latching protrusion 58(FIG. 7) may extend axially from or near the axially extending endsegments 54 to form a snap lock connection described later.

A first extension tube 60 is provided with threads 64, 66 on opposinglower and upper ends of the tube, respectively, preferably with externalthreads on one end and internal threads on the other end. The threads64, 66 are preferably double lead threads with one lead beginning on anopposing side of the tube 60 as the other lead. The depicted embodimenthas external lower threads 64 and internal upper threads 66. Oppositethe external threads 64 on the lower end of extension tube 60 are firstand second, locking lugs 70 (FIG. 6) extending inward from opposinginner sides of the extension tube 60 at or adjacent to the end of theextension tube 60. Each locking lug 70 is sized in its circumferentialdirection to fit within one of the first and second channels 52 a, 52 bso the extension tube 60 can slide along the outside of the first tube36. The locking lugs 70 are sized fit into the gaps formed by thestaggered axial end segments 54, 56 so that rotating the first extensiontube 60 places at least one and preferably both of the locking lugs 70between two adjacent ridges 46 or 48 on the first tube 36. The latchingprotrusion 58 advantageously engages a mating recess on the upper edgeof the adjoining locking lug 70, to snap-lock the extension tube 60 tothe first tube 36. The ends of the ridges 46, 48 and the axial endsegments 54, 56 restrain rotation of the lugs 70 and also provide anaxial strength if a worker strikes or steps on the extension tube 60.Thus, the lugs 70 hit end segments 54, 56 to stop axial movement of thetube 60 until the lugs are rotated into the channels 52 a, 52 b.

The first extension tube 60 is a known length L and by viewing thedistance reflected by the visible indicia 50 marked on the outer sidesof the first tube 36 and aligned with the lower edge of the firstextension tube 60, the length from the bottom of flange 17 on the base12 to the upper, distal end of the extension tube 60 is known. Forexample, if the lower edge of extension tube 60 is aligned with theridges 46 or 48 corresponding to printed indicia 50 indicating adistance of 3 inches from the bottom of flange 17 on base 12, and if theextension tube 36 is 5.5 inches end to end, then the distal end of thefirst extension tube 70 is 3+5.5=8.5 inches from the bottom of base 12.That system allows easy adjustment of the height of the passage tubeassembly.

When the first extension tube 60 is fastened to the first tube 36 thefree or distal end of the extension tube 60 can be closed off or anotherextension tube 60 can be added. If another extension tube 60 was addedto the above example, the distance of passage tube assembly would be3+5.5+5.5=14 inches from the flange 19 to the end of the secondextension tube 60. Additional extension tubes may be added by use of themating threads 66 on the distal end of the first extension tube 60, asseen in FIG. 9. Again, the extension tubes 60 are each of known lengthand preferably all the same length so the height to the end of a stackof extension tubes can be readily determined by adding one or moreextension tubs 60. Depending on how the end of the distal extension tube60 is closed, some length accommodation may need to be made toaccommodate for the closure.

The end of the last extension tube 60 can be closed by a cap 72 having askirt that fits inside or outside the distal end of the last extensiontube 60, but preferably the cap 72 has threads 74 configured tothreadingly engage 66 on the end of extension tube 60. The cap threads74 are thus preferably also double led threads, with one lead beginningon an opposite side of the cap as the other lead. Since the threads 66are preferably internal threads the cap threads 74 are preferablyexternal threads, preferably on a depending skirt 75 depending from aslightly larger annular top that results in an annular flange 76abutting the distal end of the extension 60 to more accurately definethe length of the tubular passage assembly 10 when the flange 76 abutsthe distal end of extension tube 60, increasing the length of tubularpassage assembly 10 by the axial length of the flange 60. The annularflange 76 abutting the distal end of extension tube 60 also provides astronger assembly to transfer forces along longitudinal axis 16 throughthe extension tube 60.

Referring to FIGS. 5-8 and 15-16, if the first tube 36 is cut to lengthbetween ridges 46, 48 and no extension tube 60 is used, or if the firsttube 36 is not cut but no extension tube 60 is used, then the cap 72 isfastened to the ridges 46, 48 on the first tube 36 by one or morelatches or lugs or snaps 78 (FIG. 14-16) extending inward from thecylindrical skirt on which the threads 74 are formed. The lugs 78 mayoptionally, but less preferably correspond to lugs 70 and fit withinchannels 52 a, 52 b and engage ridges 46, 48 in the same or similarmanner, the description of which is not repeated. Preferably though, thelugs 78 may take the form of snap locks with a surface inclined toresiliently bend and slide over the ridge 46, 48 on the distal end ofthe first tube 36 and latch into the groove between the adjacent ridges.Opposing ends of lugs 78 may be bounded by slits through the skirt 75 onwhich the lugs are formed to provide a resilient latch that can bend toslide over the ridges 46, 48. The skirt 75 of the cap 72 thus has areleasable fastening mechanism on both sides of the skirt, with capthreads 74 on the outer surface of the skirt and snap locks or lugs 78on the inner surface of the skirt.

Referring to FIGS. 1 and 12-16, the cap 72 may have an inner and outermount or connector 80 a, 80 b respectively each on respective internaland external surfaces of the cap 72. At least one and preferably twopairs of locating filaments 82 extend from a filament base 84 that isconfigured to mate with each of the connectors 80 a, 80 b. Theconnectors 80 may comprise a shaped recess or shaped protrusion, withthe mating filament base 84 comprising a protrusion or recess with amating shape. During shipment, as seen in FIG. 12, the filament base 84may be releasably connected to the inside connector 80 a of the cap 72,preferably at the center of the cap 72 so the locating filaments 82extend along the longitudinal axis 16 inside the extension tube 60and/or inside the first tube 36. The filament 82 and its base 84 may beshipped separately, but then they may be more easily separated and lostso it is preferably to ship the parts as a unit. During installation,the cap 72 is removed, the length of tubular passage assembly 10adjusted by cutting the first tube 36 or positioning one or moreextension tubes 60 on the first tube 36.

Referring to FIGS. 1, 10-11 and 13, after the length of the tubularpassage assembly 10 is adjusted, the cap 72 is screwed onto the distalextension tube 60 or latched onto the ridges of the first tube 36—butonly after the connector and locating filaments are removed from theinside of the cap 72 and fastened to the connector 80 b on the outsideof the cap 72 so the locating filaments 82 extend upward along thelongitudinal axis of the tubes and away from the base 12 of the tubularpassage.

When concrete is poured and finished, the locating filaments 82 willstick out of the concrete so the distal end of passage tube assemblycovered by cap 72 can be located. The locating filaments 82 are selectedto be thin enough to bend and not break during troweling of theconcrete, and the connector 80 and filament base 84 are configured andlocated relative to the cap 72 so the locating filaments bend at thejuncture with the connector rather than break during troweling. Nylonmonofilaments about 20 to 40 thousandths of an inch in diameter andabout 2-6 inches in length are believed suitable. The monofilamentscould be color coded to reflect the type of pipe with which the tubularpassage assembly 10 is intended for use, such as red for metal and whitefor plastic. Similarly, tabs could be provided having matching colorcoding. The removable tabs 124 are visible only from the bottom afterthe concrete deck is poured so color coded filaments 82 could provide avisible indicator from the top side of the concrete surface. Since thepipes are preferably run from the bottom up, and since the filaments 82and cap 72 may be lost or attached to the wrong passage assembly 10, theremovable tabs 124 are the preferred identification mechanism.

Referring to FIGS. 12-16, the exterior connector 80 b is preferablylocated in a recess 94 preferably a cylindrical recess centered onlongitudinal axis 16 during use. The recess 94 preferably has rounded orchamfered edges to reduce cutting, damaging or breaking of abuttinglocating filaments 82. The connector 80 b and filament base 84 are sizedso the juncture of the locating filaments 82 with the filament base 84is located below the exterior surface of the cap 72 so that when atrowel blade or float repeatedly bends a filament 82 flat against theconcrete surface the filament does not break off but resiliently resumesits position parallel to the longitudinal axis 16. The exterior, axialfacing surface of the cap 72 may have wrenching recesses 96 into which auser can insert wrenching tools, such as the jaws of channel-lockpliers, in order to help rotate the cap and remove it after concrete hashardened.

Referring to FIG. 12, during shipment, the first extension 60 may beplaced outside of and concentric with the first tube 36, with the lugs70 sliding in channels 52 and then rotated to engage the lower ridges 46or 48 adjacent base 12 to fasten the extension tube 60 to the first tube36. The cap 72 can be threadingly fastened to the threads 66 on thefirst extension tube 60, with the locating filaments 82 inside the tubes36, 60 where they will not be broken easily or lost. The cap 72 preventsdebris from entering the tube from the upper end of the assembly andthus provides a safety guard to protect personnel foot traffic on theunfinished building floor.

Referring to FIGS. 1-9 and 11-12, the flange 17 19 extending outwardfrom the base 12 can be fastened to a support 33, with FIG. 22 showing acorrugated support 33. Deck corrugations can vary from two to six inchesfrom top to bottom. The support 33 may be a flat surface such as aplywood support or other flat support during use. If the diameter of thebase 12 and first tube are large enough so they always extend across atleast two or three adjacent corrugations of a corrugated support 33 thenthe tubular passage assembly 10 is largely self-supporting and theflange 17 may mount to triangular shaped ears of a square with thecircular passage of sidewall 19 having the roughly same diameter as thelength of a square shaped flange 17 and centered in that square flange.If the diameter of sidewall 19 and tube 36 are smaller, then the baseflange 17 must extend over enough corrugations to provide a stablesupport for the tubular passage assembly 10 and to allow fastening tothe corrugated support 33 (FIG. 22). In short, larger flanges 17 may beneeded for tubular passages 10 having smaller diameter passages when thetubular passages are used on corrugated supports 33 rather than flatsupports 33.

Referring to FIGS. 1 and 17-20, if a corrugated support 33 is used, thenremovable stabilizing plates 100 may be attached to a plurality offlanges 17, preferably to opposing flanges 17. One or more, andpreferably a plurality of offset fingers 102 on one side of arectangular stabilizing plate may mate with correspondingly locatedopenings 104 along an edge of one of the base flange 17. Preferably thefingers 17 are generally rectangular strips with rounded distal endsbent to place the rounded distal ends in a plane parallel to but abovethe plane of the stabilizing plate 100. The openings 104 preferably takethe form of slots spaced to correspond with the locations of the fingers102. Each of the rounded distal ends of the fingers 102 pass from thebottom of the flange 17, through a corresponding openings 104 in theflange 17 and rest against the top of the flange 17 to connectstabilizing plates to the flange. The stabilizing plates provide a widerbase to extend across one or more corrugations of the support 33. Asdesired, stiffening ribs 105 may be formed on or in the plates 100.

The fingers 102 engage the top of the flange 17 and the adjacent portionof stabilizing plate 100 engages the adjacent bottom portion of theflange 17 to provide a stable support for the base 12 as long as weightis exerted downward along longitudinal axis 16. If the base 12 is liftedupward along axis 16, the fingers 102 of the stabilizing plate 12rotates about the edges of the openings 104 so the outer end of theplate 100 sags downward and inward toward axis 16. To prevent this aholding latch 106 preferably extends upward from the same side of theplate as the fingers 102 and the holding latch has a notch that engagesan upper side of the base 12, preferably engaging an upper surface ofbase flange 17, to keep the stabilizing plate 100 engaged with theflange 17 and to restrain sagging of the outer edge of the plate 100toward the longitudinal axis 16. A recess, preferably a slot 108 mayextend into an edge of the base flange 17 and be located to correspondwith the holding latch 106 so the holding latch can more securely engagea surface of the base 12 along a portion of the length of the slot 106.

In use, a stabilizing plate 100 is preferably but optionally fastened totwo opposing sides of the base 10 to provide a broader base for thetubular passage assembly 10. The base flange 17 preferably has a recess106 and finger openings 104 on one or more sides, preferably on opposingsides, and more preferably on each of four sides of a rectangular base,where reference to a rectangular base is used herein to include a squarebase.

Referring to FIGS. 1-4, 23 and 24A-24B, two separate but adjacentpassageway extensions 10 may be joined together, preferably at theirbase flanges 17. The base 12 a may have an elongated latch 110 extendingaway from base to engage a mating recess in a different base 12 b. Inthe depicted embodiment the base flange 17 has latch 110 extending fromthe base flange 17, preferably generally horizontally, with a latchingend 112 configured to engage a catching surface 114 on a differentflange 12 b associated with a different base 12 b. The latches 110 andcatching surfaces 114 are located so that if first and second bases 12a, 12 b are placed against each other the latch end 112 a of a firstbase 12 a on flange 17 a can engage the catch 114 b on a second baseflange 17 b to hold the two bases 12 a, 12 b together. Preferably, atleast one side of each base 12 has one latch 110 and one catch 114(e.g., a recess) located toward opposing ends of the at least one side,so that the latches 110 a, 110 b from at least two different baseflanges 17 a, 17 b engage a recess 114 b, 114 a in the other base flange17 b, 17 a to fasten at least the two different base flanges together.Different types of mating projections and recesses can be used,preferably with a male engaging member on one base 12 and a femalemember on a second base 12. While at least two adjacent tubular passageassemblies 10 may be joined this way, the joinder still allowsstabilizing plates 100 to be fastened to the sides of base 17 not joinedby the latches 110 and mating catches 112.

Also shown in FIGS. 23, 24A, 25B are a latching members preferablytaking the form of snap lock member 116 a and a mating catch 116 b eachlocated on opposing sides of sidewall 19 and located so that the snaplock members 116 a on one housing 14 a engage a mating catch 116 b onmating housing 14 b to latch the housing parts 14 a, 14 b together. Thesnap lock member and catch provide a fast connection between housingparts 14 a, 14 b. The member and catch 116 a, 116 b are located belowthe boss receiving the threaded fastener 18, on the split lineseparating the housing parts 14 a, 14 b. That split line is located on aplane containing the longitudinal axis 16.

Referring to FIGS. 17-20, for corrugated supports 33, a hole is cutthrough the corrugation support and the base 12 is positioned over thehole so the longitudinal axis 16 is centered in the hole. An extensiontube 60 is passed upward through the hole in the corrugation andfastened to the bottom of the base 12. Preferably the end of theextension tube 60 having external threads 64 passes through thecorrugation and engages base 12. The base 12 may have mating screwthreads 120 encircling the axis 16 and tubular cylinder 22 ofintumescent material and thus located outward of that cylinder 22 andaccessible from the lower end of the base. The threads 120 are doublelead threads, with one lead on each half 14 a, 14 b of the housing. Toenable the screw threads 120 to extend into the base 12 and stillencircle the tubular cylinder 22 of intumescent material, the retainingclip 24 has annular supporting surface 30 offset downward from tabs 26so that the tabs have a portion extending axially to form an axialoffset accommodating the bottom screw threads 120 with the distal endsof tabs 26 then extending outward through openings 28 in the cylindricalsidewalls 19 of the base 12 that encircle the tubular cylinder 22 ofintumescent material.

As needed, a removable adhesive cover 122 is placed over the bottom ofthe base 12 to keep debris from entering the base during shipment,installation, pouring of the concrete and subsequent application of fireretardant spray. The removable adhesive cover may be removed and placedon the open end of extension tube 60 that is screwed into the bottom ofthe base if desired. Alternatively, separate adhesive covers orremovable caps can be provided. As the extension tube 60 has internalthreads 66, an additional cap 72 could be provided and used. But sincethe bottom opening in tube 60 that is covered by adhesive cover 122 isnot normally expected to have any concrete pushing against the cover122, it need not be as strong as cap 72 onto which concrete may bepoured and onto which workers may step during use.

Referring to FIGS. 2 and 17-20 and especially to FIGS. 2 and 18, thebase flange 17 may have two removable tabs 124 a, 124 b installed intoor formed in the base, preferably in flange 17. One tab 124 a mayindicate metal and the other tab 124 b may indicate plastic. If theshaped diaphragm 40 is selected for use with metal pipe the plastic tab124 b is removed so that a user can see from looking at the remainingtab 124 a on the base 12 that the passage tube is intended for use withmetal pipes. If the shaped diaphragm 40 is selected for plastic pipesthen the metal tab 124 a is removed so that a user can see from lookingat the remaining tab 124 b on the base 12 that the passage tube assemblyis intended for use with plastic pipes. Tabs 124 may be scored,perforated or otherwise surrounded by weakened material so the selectedtab can be punched out, broken off or otherwise removed. Alternatively,the tabs 124 may be separate pieces that are selectively pressed intomating openings 126 in flange 17. This provides a way to readilyidentify at the factory which type of pipe with which the passage tubeassembly is to be used.

Referring to FIGS. 25 a and 25 b, the tubular cylinder 22 of intumescentmaterial is made of a material that expands significantly under heat soas to block off the space between the pipe and the adjacent parts of theexpandable sleeve 10 which are encased in concrete. Since plastic pipessometimes melt under sufficient heat, the tubular cylinder 22 ofintumescent material may need to expand to fill more than the spacebetween the cylinder 22 and the adjacent pipe as it may need to compressa melting and flexible walled pipe to ensure blockage of gases and waterthrough the expandable sleeve 10. In order to help the tubular cylinder22 of intumescent material conform readily it may have kinks or bends orundulations as in FIG. 25 b and may be cast in a single ring or formedin strips that are bent to conform to the surrounding structure and heldby adhesive tape or encircling bands or supports.

The height of the undulating ridges 128 relative to the adjacent valley130, and the spacing of the ridges 128 will vary with the diameter ofthe tubular cylinder 22 of intumescent material. The undulations orcrenellations are preferably evenly spaced. A preferred intumescentmaterial for these undulating cylinders 22 is as described in U.S. Pat.Nos. 6,790,893 and 6,645,278.

The tubular cylinder 22 of intumescent material is preferably extrudedor molded at a temperature below that at which the material begins toexpand significantly. Alternatively, the material may be used in flatstrips that are wrapped around molds having the desired cylindricalshape, or having an undulating walled cylindrical shape. Still further,strips of material may be impressed on opposing sides to formundulations and the strip then formed into a cylindrical shape. Ifformed of strips, the opposing ends of the strips may be left separate,but adjacent each other to form the cylindrical shape with setting ofthe material retaining that shape, or the adjacent ends may be fastenedby various fasteners such as clips, staples, stakes, adhesive, tape,etc. to maintain the shape. The strips of material formed into acylinder may also have the outer surface wrapped with and fastened to acylindrical tube of material to maintain the shape. As used herein, thereference to a “cylindrical” tube or ring of intumescent material refersto a tube or ring that is a continuous piece of material, or separatepieces abutting each other or separate pieces joined together or heldtogether—unless expressly defined otherwise.

For assembly, the appropriate base 12, tubular cylinder 22 ofintumescent material, retaining clip 24 and diaphragm seal 40 areselected for the desired type of pipe and range of pipe sizes. Thetubular cylinder 22 of intumescent material is placed into the annularbase 30 of clip 24 and the tabs 26 are inserted through the slots 28 inone half of housing 14 to wedge the cylinder 22 into place against thelip 20 and against the interior of the corresponding sidewall 19. Thenthe other half of the housing 14 is then aligned with the remaining tabs26 and the two parts of the housing 14 a, 14 b are joined and fastenedtogether in abutting relationship to form a base assembly 12. The tabs26 on retaining clip 24 are bent to inhibit removal and lock the tubularcylinder 22 of intumescent material in place against vertical motionalong one direction of longitudinal axis 16. Advantageously, bendingtabs 26 also offer increased security in retaining the assembly 10within the poured concrete, as for example, if the plastic parts areexposed to fire or fire-fighting activities such as sprays of highpressure water. Somewhere along the assembly process, the appropriatetab 124 is either removed or inserted, as the case may be, so that thetab in place on the tubular passageway 10 indicates whether the assembly10 is for use with metal or plastic pipes, resulting in a base assemblywith visible indicia indicating the type of pipe application suitablefor use with the base assembly.

After the base assembly 12 is completed, the selected diaphragm seal 40is then placed on top of the lip 20 of base 12, and the first tube 36 isattached to the base 12, preferably by engaging double lead threads 35on the tube 36 with mating threads 34 on the base 12. The stops 38 a, 38b abut to limit rotation with the parts being sized so the limit stops38 a, 38 b engage when the outer periphery of diaphragm seal 40 issecurely clamped between base 12 and first tube 36, and preferablyclamped between lip 20 on base 12 and inward extending flange 39 on thefirst tube 36. The limit stops 38 a, 38 b also locate the distal end offirst tube 36 a known distance from the base flange 17, preferably aknown distance from the bottom of the base flange 17, with the visibleindicia 50 on the tube 36 reflecting distances along longitudinal axis16 from that base flange 17. The base assembly may include the base 12,retainer 24 and intumescent tube 22 and it may be shipped separately oras part of a kit. The base assembly, diaphragm seal 40 and first tube 36may be shipped as a separate assembly or as parts of a kit, with orwithout cap 72 and filament 82 and its mount 84.

But preferably a first extension tube 60 is fit over the first tube 36and fastened thereto by lugs 70 sliding along channels 52 and rotated toengage ridges 46, 48, with cap 72 fastened to the distal end of theextension tube 60 as in FIG. 12. The filament base 84 and filament(s) 82are preferably connected inside the assembly (FIGS. 12, 14). The openbottom in base 12 may be left open, or covered by another cap 72 or by aremovable cap 122. Additional extension tubes may be shipped with thisassembly. The base assembly may be shipped by itself, or shipped as akit with the first tube 36, cap 72, cover 122, one or more extensiontubes 60 and one or more (preferably 2 or 4) stabilizing plates 100, orany combinations thereof.

A user takes the assembled base 12 and verifies it is for the type ofpipe intended for use with the passage assembly 10 by looking at tabs124. The user then adjusts the first tube 36 to the desired length bycutting the tube 36 between ridges 46, 48 using the visible indicia 50as a guide, or by adjusting the relative position of the first extensiontube 60 on the first tube 36, again using visible indicia 50 as a guide.As needed, additional extension tubes 60 may be added as described aboveto increase the length, with the position of the first extension tube 60relative to the first tube 36 reflecting fine adjustments on the fixedlength provided by the joined extension tube(s) 60. After adjusting thelength, the user fastens the base 12 to the support 33 onto whichconcrete is to be poured. As needed, the user may attach one or morestabilizing plates 100. Typically, fasteners such as screws (forcorrugated supports 33 and nails for wooden supports 33) pass throughholes 32 in the flange 17 or stabilizing plates 100 to fasten thepassage tube assembly 10 to the support 33. If a corrugated support 33is used, a hole is cut through the support 33 and the user fastens anextension tube to the bottom of base 12 by removing any protectivebottom cover (e.g., cap 72 or cover 122) and then engaging threads 64 ofextension tube 60 with threads 120 in the bottom of base 12 so theextension tube depends from the base 12. The end of extension tube 60 isthen passed through the hole in the support 33 with the distal end ofthe depending extension tube 60 covered by cap 72 or cover 122, or openas the user desires. The flange 17 and/or stabilizing plates 100 arethen fastened to the corrugated support 33.

Shortly before concrete is poured, the cap 72 is removed from the topend of the passage tube assembly. The base 84 and filament(s) 82 areremoved from the bottom of the cap and affixed to the top of the cap 72,as shown in FIGS. 9-11, 17, 20 and 22 and the cap is then put back onthe tube assembly so the locating filaments stick upward. Concrete isthen poured, with the tubular passage assembly 10 forming a casingentrained in the concrete. The ridges 46 a, 46 b and the variousprojections and changes in contour on the base 12 and tubes 36, 60 helpembed the parts in the concrete so as to inhibit removal. Optionalridges 134 may extend outward from the stepped portion 37 of the firsttube 36 to help embed the parts in the concrete, and act as labyrinthseals against the passage of moisture between the passage tube assembly10 and the concrete encasement. The depending extension tube 60 helpsprevent the concrete from entering the tubular assembly 10 from betweenthe top and bottom of the corrugations in the support 33.

After the concrete is finished and hardened sufficiently, the locationof the passage assembly 10 may be identified by the filament(s) 82sticking above the concrete. The cap 72 may be removed by inserting thejaws of a channel lock pliers in the wrenching recesses 96 and rotatingthe cap. The cover 122 or cap may be removed from the bottom of base 12or the depending extension tube 60 fastened to the base. The workers canthen pass pipes through the tubular passage assembly by passing themupwards through the opening 42 of flexible diaphragm seal 40. Theflexible, funnel shaped seal 40 allows some variation in pipe diameterand location so as to make it easier for workers to install the pipesbetween floors and to accommodate misalignments.

The ridges 46, 48 extend radially outward from the cylindrical firsttube 36. The ridges 46, 48 extend for a majority of the length of thefirst tube, and preferably extend the entire length or substantially theentire length of the tube from the stepped portion 37 to the upperdistal end of the tube. By substantially the entire length is meantabout 90 percent or more of the specified length. The ridges 46 areaxially offset from the ribs 48, such that the distance between ribs 46may be measured in inches and the distance between ribs 48 may bemeasured in millimeters or centimeters. The space between the adjacentridges 46, 48 is preferably the same within both sets of ridges 46, 48.The space between the adjacent ridges 46, 48 is preferably larger thanthe width of the respective ribs measured along the longitudinal axis16, with the space advantageously being about the width of a saw bladeused on construction sites.

Except for the seal 40, the various other parts of the passage tubeassembly 10 are preferably made of plastic, with ABS, PVC orpolypropylene plastic being preferred. The extension tubes 60 and firsttube 36 are preferably each about 5.5 inches long and overlap about oneinch with the base 12 in releasable attachment thereto. The base 12 addsabout two inches to the height of the assembly so that a base 12 andfirst tube 36 are about 7.5 inches from the bottom of base flange 17 tothe distal end of the first tube 36, with a cap adding about ⅛ inch ofadditional height that is removed after concrete is poured. Adding oneextension tube 60 increases the assembly height to about 12 inches fromthe deck or support, upon which the bottom surface of base flange 12rests. While the extension tube 60 is about 5.5 inches long, there isabout 0.5 inches of engaged threads 64, 66 on the two mating parts.Thus, the distance from the bottom of base 12 to the top of the assemblywith tubes 36, 60 represents the length of the passage from the uppersurface of the deck

If a fire occurs, the tubular cylinder 22 of intumescent material willexpand under a suitable temperature to block off air flow through theinside of the tubular passage assembly 10. If flooding occurs, theflexible diaphragm seal 40 seals against the pipe passing throughopening 42 of the seal 40, with the initial water pressing the upwardlyextending funnel portion 44 against the pipe so as to improve the sealand increase the weight of water needed to invert the seal and/or allowleakage past the seal.

Referring to FIGS. 27-30, the shaped diaphragm seal 40 may be used witha shortened housing to form an additional water seal module 140 suitablefor attachment to the passage tube assembly 10. The diaphragm seal 40 isas previously described with shaped wall 44 defining opening 42. Thediaphragm skirt 45 extends over a circular, axially extending end 142 ofa connecting ring 141 having a radially outwardly extending flange 144and may have a screw thread on the radially outward periphery of thatflange 144. The diaphragm seal 40 is against which the end of the skirt44 preferably abuts during use. The connecting ring 141 has a dependingskirt 146 below the flange 144 and an optional seal retaining recess 148immediately abutting the bottom side of the flange 144. The skirtadvantageously has threads or releasable locking tabs 150 located toreleasably engage the upper threads 66 on the extension tube 60 with theskirt 146 being configured to mate with the extension tube 60. Thelocking tabs 150 are shown as plastic tabs with a lateral latch surfaceresiliently urged outward to engage a mating ridge or thread on themating part. An optional seal 152, such as an O-ring seal, may be placedin the groove 148 to form a fluid tight seal between the skirt and theadjacent portion of the extension tube 60 during use at least sufficientto exclude poured concrete and cement.

A clamping ring 154 clamps the diaphragm seal 40 between the clampingring 154 and the connecting ring 141. The clamping ring 154 has adepending skirt 155 configured to engage the thread on the outerperiphery of flange 144 and further has an inwardly extending radialflange 154 located to abut the upper surface of diaphragm seal 40 aroundthe outer periphery of that seal during use. The clamping ring 154 hasan upwardly extending skirt 158 which may have threads thereon, withinterior threads being depicted in the figures. The upwardly extendingskirt 158 is configured to threadingly engage cap threads 74 (FIG. 1) oncap 72 during use. Other releasable engagement mechanisms can be used,such as the resilient latch 150.

During use, the seal 40 is clamped between flanges 144, 156 of theretaining ring 141 and clamping ring 154, respectively. The mating rings141, 154 fix the periphery of the diaphragm seal 40 while the opening 42in the seal 40 allows a flexible fluid seal with the tubular memberpassing therethrough. The water seal module 140 may be affixed on theupper or lower end of the passageway 10 so as to be flush with thepoured concrete and embedded therein. It provides a second water sealfor redundancy. The removable cap 72 keeps debris out during pouring ofconcrete and is removed for insertion of the pipe etc. through theopening 42 of the diaphragm.

Referring to FIGS. 27 and 28, the diaphragm seal 40 is shown with anoptional, axially extending rim 159. The rim 159 is integrally moldedwith the seal 40 and extends for a short distance along the length ofthe longitudinal axis 16. The rim 159 strengthens the opening 42 in theseal and helps reduce tearing and unintended enlargement of the seal.The rim also provides additional resistance to expansion and helps forma tighter seal with the elongated members passing through the sealopening 42.

Referring to FIGS. 31-33, the water seal module 140 module is connectedto the end of extension tube 60 on the bottom, and connected to a dam160 on the upper end of the module 140. The dam 160 preferably threadsinto the threads on the upper skirt 154 of the water module 140 toprovide a tubular barrier or dam a few inches high to prevent water ordebris from entering the opening formed by the extension tube 60 andother parts of the passageway 10. The dam 160 comprises a tube,preferably cylindrical and having a bottom end configured to mate withthe upper end of the water module 140. The lower end of the water module140 is shown as engaging the upper end of extension tube 60, withinternal threads or other locking mechanisms configured to engage thelocking tab 150 on the skirt 146 of the water module 140.

The dam 160 may have a length of a few inches, preferably about twoinches and advantageously less than 6 inches. After the tubular passage10 and/or water module 140 or extension tube 60 is embedded in aconcrete floor, the cap 72 is removed and dam 160 is fastened to theupward opening end of the passageway 10, extension 60 or water module140. Affixing the dam 160 forms a short barrier at floor level and helpsprevent water and debris from easily flowing into the passageway formedby passage tube assembly 10 or water module 140. The dam 160 is short inlength so that it doesn't block access to the assembly 10 and so it doesnot unduly hinder passing elongated members through the assembly 10 ormodule 140. The flange 158 may be ribbed to provide better interlockingwith the concrete that embeds the flange during use, with the figuresshowing one exemplary ribbed design that may also provide grippingsurfaces to rotate the parts during installation and use.

Referring to FIGS. 34-35, an aerator box 170 is shown in connection withthe passage tube assembly 10. The aerator box 170 has two opposing, flatsides 172 spaced apart a distance that is about the same as thecorresponding edges of the flange 17 on base 12 and larger than thediameter of the passageway through tube assembly 10. The flat sides 172are each joined by an end wall 174 to encircle axis 16 and form thesides of a box enclosure with the end walls 174 being shown with acurved shape. The aerator box 170 has a top 176 joined to the top edgesof sides 172 and ends 174 and having an axially extending and preferablythreaded cylindrical flange 178 extending therefrom. The flange 178 isconfigured to fit inside and threadingly engage threads 120 on the base12 (FIGS. 16, 20), just as extension tube 60 does. Opposite the top 176and its flange 178, is an outwardly extending flange 180 that isconnected to and preferably extends radially outward from the sides 172and ends 174.

The sides and ends 172, 174 and top 176 form the aerator box 170 todefine an enclosed space. The flange 178 connects the aerator box 170 tothe base 12. The outwardly extending flange 180 allows the aerator box170 to be fastened to a sheet or form for pouring concrete. The ends 174are spaced further apart than sides 172, and sides 172 may be close tothe outer diameter of flange 178. The extra space allowed by the largerspacing between ends 174 provides an enlarged cavity in the pouredconcrete to allow access and air flow to the base 12. The ends 174 areadvantageously spaced a distance apart that is less than about twice thedistance between sides 172. The ends 174 are preferably about 4-8 inchesfurther apart than flat sides. That allows a space about 2 inches onopposing ends of the aerator box to accommodate hands or wrenches or airflow. Sides 172 are preferably flat so the assemblies can be placedside-by-side or ganged with minimal space usage, while ends 174 arepreferably curved to reduce stress concentrations in the concrete. Thejunctures of sides 174 and ends 174 are preferably curved with a radiuslarge enough to avoid high stress concentrations in the concrete slabwhen concrete entrains the aerator box 170.

The aerator box 170 also allows plumbing fittings, such as elbow 182 tofit further into the concrete before connecting to base 12, and thatallows the pipe 184 connected to the elbow 182 to extend along and veryclose to the poured concrete surface without requiring an elbow fittingwith unequal length legs.

Referring to FIGS. 18 and 36, in FIG. 18 the two stabilizing plates 100were each removably attached to the flange 17 of base 12. In FIG. 36 thetwo stabilizing plates are integrally formed from a single piece ofmaterial, such as by punching or cutting the desired openings 32,fingers 102 and stiffening ribs 105, in order to form unitary, enlargedelongated plate 188. A circular opening 190 is formed in the plate 188.Preferably the opening 190 is about the same as the width of the plate,leaving enough structure joining the opposing ends so that the platedoes not bend under its own weight during normal handling by users forinstallation. The opening 190 is also about the width needed to allowaccess to the threads 120 in the bottom of the base 12 so the extensiontube 60 or elbow 182 may pass through the opening 190 to be connected tothe base 12. The fingers 102 are located and configured to extendthrough the mating holes 104 in the flange 17 of base 12. The fingers102 may be bent sideways or twisted to interlock the elongated plate 188with the flange 17. In the depicted embodiment there are two rows ofshort, generally rectangular fingers 102, parallel to each other andaligned to mate with corresponding slots 104 in the flange 17 of base12. If the flange 17 and base 12 are made of polypropylene or othersuitably pliable material and if the fingers 102 made of metal it isbelieved that the flange 17 is sufficiently pliable that the fingers 102may be forced into the flange without slots 104 in order to fasten theelongated plate 188 to the base 12 and flange 17. The forcing of thefingers 102 into the polypropylene flange 17 is facilitated if thepenetrating edge of the fingers 102 is pointed or inclined.

Referring to FIGS. 37 a, 37 b and 37 c, a further embodiment of cap 72is shown. The cap threads 74 and skirt 75 are the same as describedpreviously. The prior cap of FIG. 13-16 had an annular flange 76 with anouter peripheral side that was generally parallel to longitudinal axis16 and of the same diameter as the outer periphery of the part 36, 60with which the cap threads 74 engaged. The cap of FIGS. 37 a, 37 b has atop flange with an outer peripheral side 192 that is inclined inwardlyto form a short, conical section that is tapered at an angle of about 23degrees from the vertical along axis 16 and at an angle of about 67degrees from a plane orthogonal to axis 16. The angle of inclination canvary greatly as long as the described functions are achieved, butpreferably the angle is between about 45-75 degrees from the orthogonalplane and about 15-45 degrees from the axis 16. The inclined periphery192 is located radially outward of or axially spaced apart from outwardfrom the adjacent surface of the tube 36 or 60 with which the capthreads 74 engage. Thus, the inclined periphery 192 forms a short,conical, inclined surface in the concrete when the concrete slab ispoured and entrains the sides of the cap 72 and the cap is then removed.The concrete surface is poured flush with the top of the cap 72 and theinclined periphery surface 192 forms a beveled entrance to the tubularpassage 10. The inclined or beveled surface in the concrete formed bythe inclined sidewall 192 angles the otherwise 90 degree, sharp cornerof the prior cap, reduces stress concentration in the resulting concretesurface found at the sharp corners, and may help guide the pipe into thepassageway formed by the passage 10 and/or tubes 36, 60.

After the concrete cures the cap 72 may be hit with a hammer or otherdevice and the inclined periphery 192 more easily releases the adhesionbetween the cap 72 and the embedding concrete slab and thus allows thecap to be more easily removed than does a periphery of the cap 72 isconcentric with the axis 16. Thus, the top outer side 192 of the cap ispreferably angled inward toward the threads 74 and extends outward fromthe abutting body of tube 36, 60 to form a conically inclined or beveledsurface in the concrete. As the outer periphery abuts the upper end oftube 36 or extension tuber 60, the cap shape may vary slightly with thenature of the juncture of those parts. The cap of FIGS. 37 a, 37 b hasthe inclined periphery surface 192 extending from the skirt 75 on whichthreads are formed and the length of that surface 192 preferably extendsaxially a distance sufficient so a portion of the inclined surface 192extends beyond the outer diameter of the extension tube 60 in order toensure a beveled surface is formed in the concrete. As shown in FIG. 37c, the inclined surface 192 is spaced radially outward from the skirt 75on which the threads 74 or other engaging mechanism are located andspaced outward a distance about the same as the thickness of theextension tube 60 which is sufficient to allow the inclined side 192 toform a beveled opening to the concrete surface when the sidewall 192 isentrained with concrete to the level of the top of the cap 72. In FIG.37 c, there is an annular, axial facing surface at the bottom of theinclined surface 192 which preferably places the bottom of the inclinedsurface at the outer periphery of the extension tube 60 when the cap isfastened to the upper end of that extension tube for entrainment inconcrete.

Referring to FIGS. 38 a-38 d, an alternative embodiment of the base 12and its flange 17 and stabilizing plate 100 is shown. The split, twopart base 12 with its associated and flange(s) 17 are substantially aspreviously described and held together by fasteners 18 a engaging bosses18 b and 18 c. But the flange 17 is modified. The distal end portion ofat least one, and preferably of two opposing sides of the base flange 17may be elongated to form a supporting plate 200 that is connected to theflange 17 so the supporting plate 200 may fold upward toward andpreferably connected to sidewall 19 of base 12. A hinge 202 allows therotation of the supporting plate(s) 200 with the portion outward of thehinge 202 forming the supporting plate 200 or distal end portion.Preferably a living hinge 202 may be used and it may be formed bymolding, scoring, cutting or otherwise forming a sharply reduced crosssection in the thickness of the flange 17 to define a weakened line 202which may bend and form a living hinge 202. The hinge 202 is preferablyformed in the bottom surface of the flange 17 (FIG. 38 d). Morepreferably the base 12, flange 17 and supporting plate(s) 200 areinjection molded plastic to form a unitary, integrally molded part, thatis formed at the same time, with a reduced area forming the living hinge202. The living hinge 202 preferably extends from side to side acrossflange 17 and has a width that is less than the thickness of the flange17 at the location of the hinge 202. Advantageously, the depth of thegroove forming the living hinge 202 is less than half the thickness ofthe flange 17 at the location of the hinge 202. The material of theflange 17 is also appropriately selected to allow repeated bending ofthe supporting plate 200 about hinge 202 without fracturing after beingfully flexed 5-10 times. A polymer material is preferred, withpolypropylene being believed suitable. In a less preferable embodimentthe material of flange 17 and the groove forming hinge 202 are selectedof a more brittle material or material susceptible to fatigue failure sothat the groove forming hinge 200 forms a frangible line allowingsupporting plate 200 to be broken off along the hinge 202 by fullyflexing the hinge 202 a few times, preferably less than five times andmore preferably 2 or three times.

When in the deployed position substantially in the plane of flange 17the supporting plate(s) 200 extend the supporting flange 17 over alarger area and preferably over abutting or adjacent corrugations 33(FIG. 22). By forming a living hinge, the flange 17 is relatively stiffunless and until the supporting plates are first rotated about hinge 202and that makes handling easier. The supporting plates 200 may havefastener openings 32 therein so the plates 200 may be fastened to theconcrete forms and such fastening greatly stiffens the flange 17 andplates 200 until concrete is poured over the assembly. If space is tightor if one or more passage tube assemblies 10 are ganged togetheradjacent one another, then the extended supporting plates 200 areundesirable. Rotating the supporting plates 200 about hinge 202effectively takes them out of the way to allow close nesting and gangingof the bases 12 and passage tube assemblies 10. By having the hinges 202connect the supporting plates 200 the complexity of handling multipleparts is avoided and the risk that the detachable supporting plates 100will be lost or not readily available when needed is also avoided.

The supporting plate(s) 200 may be rotated about living hinge 200 towardbase 12 sidewall 19 of the base 12 with a latch 204 (FIG. 38 c)extending outwardly from the sidewall 19 a or 19 b to releasably engagethe adjacent supporting plate 200, usually at an edge of the plate or atan opening formed in the plate 200 at a location to be engaged by thelatch 204, or by a mating latching surface connected to the plate andlocated to be engaged by the latch 200—depending on the length of theplate 200. In the depicted embodiment the latch 204 is a planar flangeextending vertically in a radial plane and having a right-angled notchin it (FIG. 38 a, 38 c) so the supporting plate 200 may rest against thelower, inclined portion of the notch and limit the rotation of the platetoward the base 12, while the upper and outer edge of the notch latchesthe plate 200 into position. An elongated latching member or beam latch204 lacking any rotation stop, is also believed suitable.

Preferably there are two hinges 202, located on opposing sides of thesidewall 19, and spaced apart the same distance as the two adjacentsides of the flange 17 so as to form a square flange 17 when thesupporting plates 200 are latched to the sidewalls 19 a, 19 b by thelatches 204. In the depicted embodiment the supporting plates 200 have alength measured outward of the hinge 202 that is about half the heightof the base 12 measured along axis 16—as best seen in FIG. 38 c. But thelength of supporting plates 200 may vary, with the location of the latch204 varying as needed to hold the plate 200 in a non-deployed position,or with various latching surfaces, edges or openings being formed in theplates 200 to engage latches 204 extending from the base 12.

FIGS. 33 a-33 d also show the connecting latches 110 and latch ends 112and latch recesses 108. The rotation of the supporting plate 200 abouthinge 202 would hit the latch 110, so an opening 206 is formed in thelatch plate 200 to accommodate passage of latch 110 through thesupporting plate 200 as the plate is rotated toward base 12 about hinge202. Likewise, an opening 206 in the supporting plate 200 allows thelatch 110 to engage the recess 108 in the mating part.

Referring to FIG. 39, a passage tube assembly 10 is shown having a base12, a first tube 36 and an extension tube 60. The first tube 36 hasfirst and second sets of ridges 46, 48 on tube 36 which ridges areseparated by corresponding grooves formed by the adjacent ridges 46 oradjacent ridges 48. The ridges and grooves are located at predeterminedlocations along the axial length of the first tube 36. The extensiontube 60 is located coaxial with and outside of the inner, first tube 36.At least one, and preferably pairs of threaded fasteners 210 extendthrough the outer tube 60 and into the inner tube 36, preferably at alocation of one of the grooves between adjacent ridges 46, or adjacentridges 48. A pilot hole 212 may extend at least part way through thewall of the outer extension tube 60, with the pilot hole preferablylocated in a boss 214 that may be molded into the side of the tube 60.Advantageously the pilot hole 212 does not extend all the way throughthe wall of outer, extension tube 60 and ends with about 0.02 or 0.03inches of wall thickness remaining. The pilot hole 212 thus dead endswithin the wall of tube 60 to form a blind hole 212. The pilot hole 212is preferably slightly smaller than the outer diameter of the threadedportion of fasteners 210. If the material of the tubes 36, 60 issufficiently flexible, the threaded fastener 210 may be much larger thanthe pilot hole 212 without breaking the tubes as the fastener isinserted.

The pilot holes 212 are located at predetermined along the axial lengthof the tube 60 which locations are selected to coincide to place thefasteners 210 between adjacent ridges 46 or adjacent ridges 48. Thethreaded fasteners 210 are preferably self-taping or self-drillingscrews of a material suitable for use with concrete and the material ofthe tubes 36, 60, and are preferably of steel or stainless steel. Oncethe length of the tube 36 and outer tube 60 are selected to place thetop of the passageway 10 at the desired location of the concrete surfacewithin which the passageway 10 will be embedded, the screws 210 aredriven through the blind end of the pilot hole 212 in outer tube 60,across any gap separating the tubes 36, 60, and into the wall of theinner tube 36 so as to secure the two tubes 36, 60 together. Preferablypilot holes 212 are located on diametrically opposing sides of tube 60and preferably there are two pilot holes 212 vertically aligned along anaxis parallel to axis 16, on each opposing side of tube 60. Thefasteners 210 guard against unintended changes in the length of thepassage tube assembly 10 during construction. A fastener 210 on eachopposing side helps avoid tilting of the outer tube 60 relative to theinner tube 36 and helps maintain the cap 72 parallel to the desiredexterior surface of the concrete within which the passage tub assembly10 is to be embedded. A pair of fasteners 210 are preferably used oneach side to prevent tilting about a plane through axis 16 andcontaining the fasteners 210, and to make the position and configurationof the passage tube assembly 10 more stable.

Because the locking lugs 68, 70 on the extension tube 60 position thetube 60 relative to the inner, graduated tube 36, the relative locationof the two tubes 36, 60 are known, and thus the location of the ridges46, 48 relative to a point on the outer surface of tube 60 is also knownor determinable. The location of the pilot holes 212 relative to theridges 46, 48 may thus be determined. The pilot holes 212 may thus belocated so that the threaded fasteners 210 extend between adjacentridges 46 or through them, or between adjacent ridges 48, or throughthem. Advantageously the threaded fasteners 210 comprise self-tapingscrews with an outer thread diameter larger than the space between twoadjacent ridges 46 or two adjacent ridges 48 and the pilot holes 212 arelocated so the fasteners pass between those two adjacent ridges andthreadingly engage two adjacent ridges 46 or two adjacent ridges 48. Thebosses 214 are optional, but make it easier to locate the pilot holes212. A boss 214 with an annular outer rim surrounding a recessed innersurface centered around pilot hole 212 is preferred.

The tube 36 thus has a plurality of first ridges 46 that are equallyspaced apart a distance sufficient to snugly receive one of locking lugs68, 70 on the extension tube 60, and preferably has a plurality ofsecond ridges 48 also equally spaced apart a distance sufficient tosnugly receive one of locking lugs 68, 70, with the first set of ridges46 axially offset from the second set of ridges 48. The pilot hole(s)212 may be located relative to the received locking lug 68, 70 so as tobe located in a radial plane passing between two adjacent first ridges46 when one of the locking lugs 68, 70 is received between two firstridges 46, and preferably located in the middle of two such adjacentfirst ridges. The pilot hole(s) 212 may also advantageously locatedrelative to the received locking lug 68, 70 so as to be located in aradial plane passing between two adjacent second ridges 48 when one ofthe locking lugs 68, 70 is received between two first ridges 46, andpreferably located in the middle of two such adjacent first ridges.

Referring to FIGS. 40-41, the extension tube 60 may have stiffening ribsin order to increase the strength of the passage tube assembly. The tube60 may thus have circumferential ring stiffening rings 220 located alongthe axial length of the tube 60, or it may have longitudinal stiffeners222 extending parallel to the longitudinal axis 16 along the axiallength of the outer surface of the tube 60. The stiffeners 220, 222extend outward from the exterior or outer surface of tube 60 and mayextend radially outward and are preferably of the same cross-sectionalshape. The stiffeners 220, 222 may have various cross-sectional shapesbut preferably a cross-sectional shape is selected that allow thestiffeners 220, 222 to be molded by a two-part mold with a vertical moldseparation line.

Depending on the strength desired for the tube 60, the stiffeners 220,222 may have various shapes and various numbers of rings or stiffeners.For stiffening rings 220, the cross-section is smaller at the outermostend and wider at the innermost end which joins the outer surface of thetube and shapes having slightly rectangular cross-sections orsemi-circular cross sectional shapes are believed desirable, and thecross-sectional shapes are preferably solid.

For longitudinal stiffeners 222 the orientation of the stiffenerspreferably alters to accommodate a two part mold, with each longitudinalstiffener or stiffening rib 224 having a height extending along an axisparallel to the axis 144 (FIG. 41) along which the mold is withdrawn,with the molds separating along mold separating line 225. Thus, as seenin FIG. 41, the longitudinal stiffeners 222 on opposing sides of bosses214 are almost radial in orientation while the rigs 90 degrees theretoare radial in orientation, but the ribs in-between become moretangential or inclined since the rib height is parallel to the axis 224.The depicted ribs 224 thus have a varying actual height but preferablydo not extend outward beyond the radial outward diameter of the flangehaving internal threads 66. The longitudinal ribs 224 may be about 0.1inch to ⅛ inch wide with the height varying as described. On the insideof the extension tube 60 of FIG. 41 are shown some slightly raisedlongitudinal bosses 226 that are added for molding convenience. Thebosses 226 are about 0.02 inches high for a tube 60 that is about 4.5 to5 inches in diameter as shown in FIGS. 40-41.

The stiffeners 220, 222 allow greater load to be carried along the axis16 and to accommodate that increased load the various threads 16, 35,64, 66 may be buttress threads, or ACME threads or other type of powerthreads in order to carry the increases axial forces without shearingoff or breaking the threaded connections among the parts. The threadsare preferably integrally molded with the various parts (base 12, tube36, tube 60) and are thus of the same type of material, preferablyplastic, as the various parts. But the threads 16, 35, 64, 66 could bemade of metal and either over-molded into parts made of plastic such asbase 12, tube 36 or tube 60, or otherwise secured in the plastic part.There are thus provided circumferential stiffening ribs 220 orlongitudinal stiffening ribs 222 to strengthen the extension tube 60.

Although these inventions have been disclosed in the context of certainpreferred embodiments and examples, it will be understood by thoseskilled in the art that the present inventions extend beyond thespecifically disclosed embodiments to other alternative embodimentsand/or uses of the inventions and obvious, modifications and equivalentsthereof. In addition, while several variations of the inventions havebeen shown and described in detail, other modifications, which arewithin the scope of these inventions, will be readily apparent to thoseof skill in the art based upon this disclosure. It is also contemplatedthat various combination or sub-combinations of the specific featuresand aspects of the embodiments may be made and still fall within thescope of the inventions. It should be understood that various featuresand aspects of the disclosed embodiments can be combined with orsubstituted for one another in order to form varying modes of thedisclosed inventions. Thus, it is intended that the scope of at leastsome of the present inventions herein disclosed should not be limited bythe particular disclosed embodiments described above.

What is claimed is:
 1. An assembly forming a tubular passage for pouredconcrete decks formed on a support surface, comprising: a base having acylindrical sidewall with an upper end and an opposing bottom end andextending along a longitudinal axis, the upper end of the sidewallhaving an inward extending upper flange defining a circular opening, thelower end of the base having an outward extending base flange to supportthe base on the support surface during use; an tubular cylinder ofintumescent material fitting inside and adjacent to the sidewall andrestrained from movement in a first direction along the longitudinalaxis by the upper flange, the tubular cylinder of intumescent materialencircling the longitudinal axis and retained in position along thelongitudinal axis during use; a first flexible diaphragm seal having anouter periphery engaging an upper end of the base and having an innerperiphery defining an opening encircling the longitudinal axis duringuse, a portion of the diaphragm adjacent the inner periphery having afunnel shape extending out of a plane orthogonal to the longitudinalaxis through the outer periphery; a first tube having opposing upper andlower ends with the lower end configured to engage the base, the firsttube having an inward extending flange adjacent the lower end configuredto engage the periphery of the diaphragm and press it against the baseto form a fluid tight seal when the first tube is engaged with the base,the first tube further including a first set of parallel ridgesextending outward from the first tube with each of the ridges in a planeorthogonal to the longitudinal axis and spaced apart a first distance; afirst extension tube having a sidewall with opposing top and bottomends, the bottom end of the first extension tube having first and secondlocking lugs each extending inward from a different opposing side of thefirst extension tube, the first and second locking lugs sized andlocated to slide along the first and second channels, respectively, withrotation of the first extension tube placing each locking lug betweentwo adjacent ridges of the first set of ridges when the first extensiontube is centered on the longitudinal axis and overlaps a portion of thefirst tube, the first extension tube having ring stiffening ribs orlongitudinal stiffening ribs on an outer side of the first extensiontube. a pilot hole extending partially through the sidewall from anexterior side of the first extension tube, the pilot hole locatedrelative to one of the first and second locking lugs so that the pilothole is located in a radial plane passing between two adjacent firstridges.
 2. The assembly of claim 1, further comprising a pilot holeextending partially through the sidewall from an exterior side of thefirst extension tube, the pilot hole located relative to one of thefirst and second locking lugs so that the pilot hole is located in aradial plane passing between two adjacent first ridges.
 3. The assemblyof claim 2, wherein there are two pilot holes on opposing sides of thefirst extension tube and further comprising two threaded fasteners, eachextending through a different one of the pilot holes and wall of theextension tube and into the first tube between two adjacent first ridgesto connect the first extension tube to the first tube, and furthercomprising two self-tapping threaded fasteners each extending through adifferent one of the pilot holes and wall of the extension tube and intothe first tube between two adjacent first ridges to connect the firstextension tube to the first tube.
 4. The assembly of claim 2, whereinthe first set of ridges extends less than half way around the first tubeand further comprising a second set of parallel ridges extending outwardfrom the first tube with each of the ridges in a plane orthogonal to thelongitudinal axis, the second set of ridges each extending less thanhalf way around the first tube and located on an opposing side of thefirst tube than the first set of ridges, the first and second ridgeshaving ends spaced apart to define first and second longitudinalchannels on opposing sides of the first tube.
 5. The assembly of claim1, further comprising a second flexible diaphragm seal having a circularperiphery located between a connecting ring and a clamping ring and heldtherebetween, the second diaphragm seal having an inner peripherydefining an opening encircling the longitudinal axis during use, aportion of the diaphragm adjacent the inner periphery having a funnelshape extending out of a plane orthogonal to the longitudinal axisthrough the outer periphery and extending in the same axial direction asthe funnel shape of the first diaphragm, the connecting ring beingconfigured to engage the upper end of the first tube.
 6. The assembly ofclaim 5, wherein the connecting ring has threads or a snap lock toengage the upper end of the first tube, with an O-ring seal locatedbetween an outward facing surface of the connecting ring and an innersurface of the first tube, the O-ring seal located between the first andsecond diaphragm seals.
 7. The assembly of claim 5, wherein the capfurther comprises: a circular top having opposing upper and lowersurfaces with a depending skirt and an inclined sidewall located betweenthe depending skirt and the top surface of the cap, the inclinedsidewall having a larger diameter adjacent the top surface of the capand a smaller diameter adjacent the skirt, the inclined sidewall havinga diameter larger than an outer diameter of the top end of the firstextension tube so as to extend outward of the first extension tube andform a beveled surface in concrete entraining the cap and firstextension tube during use.
 8. The assembly of claim 7, wherein the skirthas one of latches or threads located and configured to releasablyfasten the cap to the upper end of the first tube or the first extensiontube; and further comprising: a mount on at least the upper side of thetop, the mount located in a recess; and a connector having at least onefilament extending therefrom, the connector configured to releasablyengage the mount to hold the at least one filament generally parallel tothe longitudinal axis, the engagement of the filament to the connectorbeing located below the upper side of the top and sufficiently far fromthe recess so that the at least one filament can be troweled against theupper side of the top and not break, the filament having a lengthsufficient to be visible after the cap is covered with a thin layer oftroweled concrete during use.
 9. The assembly of claim 1, wherein theconnecting ring has threads or a snap lock to engage the upper end ofthe first tube, with an O-ring seal located between an outward facingsurface of the connecting ring and an inner surface of the first tube,the O-ring seal located between the first and second diaphragm seals.10. The assembly of claim 1, further comprising an aerator box havingtwo parallel side walls joined at opposing ends to a different one oftwo opposing end walls, the side walls and end walls connected to a tophaving a cylindrical flange configured to connect to the bottom of thebase, the parallel side walls being spaced apart the same distance astwo opposing sides of the base flange, the two opposing end walls beingspaced apart a larger distance but less than twice the distance betweenthe parallel side walls, at least some of the end walls and side wallshaving a lower end with an outwardly extending flange suitable forfastening the aerator box to a concrete pouring form.
 11. The assemblyof claim 1, wherein the base flange has two opposing and parallel sidesand two opposing ends, each of the opposing ends having a hingeextending across the end orthogonal to the sides and forming a distalend portion that may rotate about the hinge toward the sidewall of thebase
 12. The assembly of claim 11 wherein the hinge is a living hingeformed in a base flange made of a polymer.
 13. The assembly of claim 11,further comprising a ring having a short axial width of a few inches andhaving a circular connector configured to sealingly engage the upper endof the first tube or the first extension tube to form a dam after theassembly is encased in concrete.
 14. The assembly of claim 1, furthercomprising a support plate having an opening encircling the longitudinalaxis and allowing access to the bottom of the base, the support platehaving a length sufficient to extend beyond the ends of two opposingends of the base flange, the support plate having a generally planarshape with a plurality of fingers extending from an upper surface of theplate, the fingers configured to pierce the base flange and connect thesupport plate to the base flange.
 15. The assembly of claim 1, furthercomprising a support plate having an opening encircling the longitudinalaxis and allowing access to the bottom of the base, the support platehaving a length sufficient to extend beyond the ends of two opposingends of the base flange, the support plate having a generally planarshape with a plurality of fingers extending from an upper surface of theplate, a plurality of the fingers configured and located to extendthrough a plurality of slots extending through the base flange toconnect the support plate to the base flange.
 16. The assembly of claim1, wherein the stiffening ribs comprise ring stiffeners.